Static and Dynamic Simulations

Various types of mechanical load simulations are possible with modern FEM (Finite Element Method) software. Physixfactor performs many mechanical simulations for industry such as:

  • mechanical loads and critical stress modal analysis,
  • analysis of vibrations and resonances
  • hyperelastic materials, such as rubber components
  • contact surface analyses
  • frequency analyzes to improve frames and constructions.
  • Seismic loading of structures

The safety or robustness of your products or designs are often the starting point for an analysis.

Vibration Cutting Tool

Design Cutting Tool with low frequency

Unwanted vibrations can eventually tire structures, increasing the risk of failure. Where are the natural frequencies of a system, and which parts are critical? How can you avoid these unwanted vibrations? Through a thorough analysis with the application of the correct preconditions the product will improve.

Design Hyperelastic Seal.

Rubber or silicone material can sometimes become very elongated. Due to these properties, they are used in all kinds of products. Such as seals and the like. As shown here, the rubber material is pulled over a ring, and to prevent cracking, the elongation must remain within certain limits. In this simulation, the forces that the rubber material exerts over the ring during movement are simulated. With this product, the sealing force was important during the entire movement to avoid leakage of liquids. Laboratory tests showed a good match with the simulations, allowing the possibility to optimise and predict product changes. Read more….

Hyperelastic seal

Design Heavy Duty Axis.


After how many revolutions can a heavily loaded axle fail?
A roller is designed to last for many rotations. Under its own weight, constantly changing loads will occur that can lead to breakage in the suspension points. The number of rotations for this design was 10 billion during which the system had to continue to operate without problems. Material data is important for this type of calculations and a sufficiently fine mesh to properly calculate the peak stresses during rotations. During this project, measurements were also made on the surface roughness, because this plays a very important role with regard to the reliability of the simulation.

Where is the tension or mechanical stress greatest? FEM simulations are very efficient to determine the maximum stress in structures. This part is used in an electric truck as a carrying bracket for batteries. During use, not only static gravity is important, but also the prescribed dynamic loads. The chissel must be strong enough for speed bumps and, for example, an emergency stop.


Design Seismic Loaded Construction

Is the structure strong enough to withstand an earthquake?

A well-known standard that is applied is ASCE 7-10, which contains provisions on how this structure should be loaded. It is important where in the world the structures are built. For example, an industrial construction in the open field is loaded differently than a sensitive production machine for the chip industry, for example. Physixfactor has experience with these seismic calculations and works closely with a third party in this area.

Contact Mechanics and Deformation

Does deformation occur at contact surfaces?

An important part is to avoid the stresses that occur perpendicular (normal direction) or parallel (tangential direction) to the contact surface. Parts that come into contact with each other, such as gears, exert forces on each other. If it concerns different materials, the hard material can penetrate into the soft material. The forces can be high and the contact surface can permanently deform if the stress exceeds the yield point. Contact mechanics is important for braking systems, bearings, friction and wear.Treedt er vervorming op bij contact oppervlakken? 
The beginning of contact mechanics studies lies in 1882, where Heinrich Hertz gives the first systematic description. Read more….

Heat Exchanger, Process Industry

How does a structure behave when it is heated up? It is known that thermal stresses can lead to additional loads or buckling in a structure. The image below simulates a heat exchanger in which very high forces were exerted on the support points during the warm-up phase, leading to wear. The simulation shows which parts absorb the greatest forces and how to reduce this through a construction change.

Thermal expansion HEX

The purpose of a modal analysis is to determine the natural vibration modes in a structure and the associated frequencies. With FEM analysis, any object can be subjected to one or more vibration sources and the effect on the structure can be mapped. In general, the lowest frequencies will be important to determine because they can be very dominant, and if desired the construction can be adjusted to shift or neutralize these frequencies. If a structure starts to vibrate at a natural frequency, the deflection can become very large if there is virtually no damping. Providing insight into the location and the way in which movements in the x, y and z directions take place is important in order to take the correct measures.

Frequency analyses

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Stress simulation of construction container